Process for making rugs and material therefor



Dec. l, 1942. y F HUTTER 2,303,936

PROCESS FOR MAKING BUGS AND MATERIAL THEREFOR Filed May 12, 1941'Patented Dec. 1, 1942 MATERIAL THEREFOR- ,4 charles F. Hutter, Austin,Tea# l Application May 12, 1941, serial No. animasv y y Y claims ,(cl.2.-278) This Iinvention relates tothe making of rugs, mats. and like'articles having a tufted or fluiy surface, and is particularlyconcerned'with the making of soecalled fluif rugs wherein relativelyshort strands of yarn or other fabric bers hav- .t

ing free ends are sewed onto a base in rows with the free vendsprojecting upwardly and dening the nap ofthe rug.

Rugs of this type have been made for generationsyboth as a domesticpastime and on a commercial scale. The present invention hasto doprimarily with making vof rugs by individuals, generally but notnecessarily in homes,'and an object of the same'is to provide a methodand`= means .whereby material for making rugs of this type may beprepared -inpackage form, or as an article of manufacture, and sold inthe open market and thereafter applied to a'suitable base easilyvandaccurately. 1 f Another object is to provide a process of pre-v paringmaterial for fluff rugs' by means of which rug making will be rendered apleasant as well as a profitable diversion to people in homes or otherplaces where they may be able to utilize spare time and which willensure accurate rug making irrespective of experience in this field.

In practicing my improved method, strands of fabric fibers such as yarn,string, twine or other material capable of providing a suitable nap arewound-on a form or core, preferably cylindrical in, shape, and holdingstrips of adhesive such as paper, Cellophane or the like are thenapplied to the coils at right angles to the latter and in spacedrelation to one another. The material may then be removed from thecylinder in the form of a layer or square by cutting along one of thespaces between a pair of adhesive strips.

In applying the material to -a base, it is separated into bands bycutting along alternate spaces between the strips of adhesive, and eachband so separated is attached to the base as by stitching, either with asewing machine or manually, the line of stitching being made along thespace between each adjacent pair of adhesive strips. As one band of fluior nap is laid or attached, the adhesive strips are removed therefromand a succeeding band of fiui or nap laid in a like manner, the spacingof the bands with respect to one another as well as the closeness of thecoils on the cylinder determining the thickness of the tufts or nap ofthe rug.

A single core may be used as a form and the material cut from the coreand packed in layers and sold in the open market in this manner, or thematerial may be sold on the cores.

The accompanying. drawing is'illustrative of the process and therein:v`f

Fig. 1 shows a cylinder of prepared rug material; l l, j. 1;; .I

Fig, 2 is an end view,of`Fig."l; u

Fig. 3 shows a layer or square of material re-l moved from the cylinderready for cutting in bands; Y i

Fig. 4 shows one of the bands being applied to a base; f

Fig. 5iis anedge elevation showing one band attached and a succeedingadjacent band inthe process of being laid; f

Fig. 6 is a perspective view ofa portion of a completed rug. l'

The numeral' Iii designates..` a cylindrical form orcore which may bemade of cardboard, having wound thereon a continuousastrandy of'materialsuch as-yarn, string, threadorthe like 'indicated at I I. Thewindingsi'of'the strand' H. may be compactl or--spaced apartdependingupon. the desired density or thickness-0f the tuftl or nap. Strips ofadhesiveIZ Aarethen applied lengthwise of the cylinder with the stripssubstantially uniformly spaced from one another, defining alternatelongitudinal severing and stitching spaces I3 and I3. These retainingstrips may consist of gummed paper, Cellophane or the like. The materialmay then be removed from the form or core I0 by cutting along any one ofthe spaces I3 or I3' and laid out in the form of a square, note Fig. 3.These squares may be packed or packaged and sold in the open market.

In applying the material to a base Iii, it is separated in bands bycutting along the space I3, for example, to produce the band ofpredetermined short length strands shown at the top of Fig. 3, and thisband is attached to the base by stitching along the space I3'; note Fig.4. This may be done with an ordinary sewing machine, and in fact themethod is conducive to the use of a sewing machine. After one band ofnap or iiui severed strands has been attached to the base, the adhesivestrips which are of a width substantially equal to one half of thelength of the severed strands are removed and a succeeding nap band isplaced parallel to the attached band and sewn to the base in a likemanner as indicated in Fig. 5. The spacing of the bands in conjunctionwith the compactness of wind of the coils determines the density of thefluff or nap.

If desired, each alternate longitudinal space may be slightly greaterthan the intermediate space, with the narrower space defining the lineof sewing and the slightly broader space defining method of preparingmaterial stimulates interest and ensures an attractive job byinexperienced persons.

It will be understood that the material may be wound on any type of formor core desired, either cylindrical, square, oblong or the like, andthat thestrands may be either continuous or' in` un,-

connected lengths, although they are preferably continuous, and thatthese and other modifications mayn bemade Without departing from thespirit or scope of the invention asrdened by the appendedclaims.

What is claimed is:

1. The methodofj makingrugs or the likethat includes. the followingsteps; forming a layer of longitudinally disposed fibers, attaching tosaid layer a series of spaced apart removable holding stripstransversely arranged With respect to said fibers, severing said layertransversely WithV respect to. said. bersinto a plurality of bands offibers. held. in position by a pair of said spaced apart holding strips,securing a plurality of said bands in side by'side relationship to abasealong the space between said pairs of holding strips,andsubsequently removing said holding strips from said bers. A

2*.. Armethod of makingrugs or the like that includes.` the followingsteps; winding. ak layer oflongitudinally. disposed fibers, on a form,adhesivelyv attaching to one surface of said layer a series of spacedapart holding strips transversely arrangedwith respect to. said fibers,severing said layer transversely withlrespect to said flbers to formthereby a plurality ofbands of said fibers held in position by a pairof` said spaced apart holding strips, stitching a plurality of saidbands in side by side relationship to a rug base along Vmaterial securedtransversely over said strands,

said adhesive strips being substantially uniformly spaced from oneanother along the length of the strands, said retaining strips being ofa Width substantially equal to one half the length of the severedstrands, each alternate space defining a line of severance for-cuttingthematerial into said: bandstof predeterminedlengthzstrands, and theother alternate spacesxservingf as: guidesfor stitching the severedstrandsjtoazsuitable base; saidV adhesive strips, being; removablyapplied' so that after the stitchinghasbeen. completed', they may bereadily removed togrelease the severed strands on opposite sides ofeaclrline' of stitching and provide a` nap of a length. Substantiallyequal to the Width, of said:A strand-retaining strips.

4. As an article of manufacture, rug material comprising a bandformedofa layer of. parallel tlosely'disposed severedstrandsof uniformlength;

and a pair 'of' closely spaced: strandiretaining strips of readilyremovableadhesive material: secured transversely ofA the strands.` fromend to end of the band,'said' stripsA each bengiof a Width substantiallyequal tojonehali thelength of theY severed; strands, and the spacebetween thestrips serving as al guide-.for -stitching--'the severedstrands directly to a-suit'able base. CHARLES F.

